Calculator · 4 min

Put-wall & sorting-station sizer

Estimate how many order cubbies and sorting workstations are needed.

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Your numbers

Describe your operation

Example values are already filled in so you can see how the tool works. Replace them with measurements from your operation. Results update immediately.

Open the plain-English glossary

This tool sizes a put wall—not a picking cart

It estimates order cubbies and sorting workstations. Cart size still depends on order size, route, and the number of orders kept separate.

Peak orders / hourOrders entering this process during a busy hour that is typical enough to plan around.

Example: 180 orders/hourAverage slot dwellMinutes from the first item placed in a cubby until the completed order leaves it.

min

Example: 18 minutesShort-window peak factorA short burst inside the already busy hour.

Example: 1.25× allows 25% above the hourly averageTarget slot occupancyHighest share of cubbies you plan to keep occupied. Empty space prevents gridlock.

Example: 82% occupied leaves about 18% freePeak lines to sort / hourProduct lines that must be placed and confirmed at the sort area during the busy hour.

Example: 680 lines/hourSort seconds / lineAverage worker seconds to place and confirm one line at the wall or sorting station.

sec

Example: 9 seconds/lineTarget sorter utilizationShare of calculated sorter time you plan to schedule, leaving time for normal delays.

Example: 82%

Show the math and assumptions

Orders in cubbies at once = orders per minute × average minutes in a cubby.

Required cubbies = concurrent orders × short peak factor ÷ planned occupancy.

How to read this

The yellow result is the main planning answer. Change any uncertain input to see whether the answer is stable. Treat this as a starting point for a small real-world test, not a promise.

Concurrent orders54Average orders occupying cubbies at the same time.

Required wall slots83Cubbies needed after applying the peak factor and open-space target.

24-slot wall modules4Number of 24-cubby wall sections; 24 is a fixed planning assumption.

Parallel sort stations3Sorters or workstations needed at the same time.

Nominal slot turns / hr3.33Times one cubby could be emptied and reused in an hour at the average dwell time.

Target slot occupancy82%The planned share of cubbies allowed to be occupied so some space remains for variation.

Check physical order size too. A cubby count does not prove the cubbies are large enough. Measure a large order size that about 95 out of 100 orders do not exceed.

What to check nextMeasure cubby waiting time from the first item placed until the complete order leaves. Check separately for missing-zone items, blocked complete orders, packing delays, and carrier holds.

After the calculation

Test the answer on a small piece of real work.

Measure today’s result first. Write down what success means, what can go wrong, and how workers will continue if the new method fails.

Plan a small trial Build a go-live test